Electrical connector assembly



-Fun@ 30, 1970 Filed April 17. 1967 H. P. SPARKES ET AL ELECTRICAL CONNECTOR ASSEMBLY 3 Sheets-Sheet 2 ',fff/ DOUGLAS E BowMAN ,f ANTHONY J.PUSATER|,JR. BY

'In' v Y l Agent `Fume 30, 1970 H. P. sPARKEs ET Al. 3,518,615

ELECTRICAL CONNECTOR ASSEMBLY 3 Sheets-Sheet 5 FiledV Aprn 17. 19e? INVENToRs. HARRY P. SPAR KES DOUGLAS F. BOWMAN ANTHONY J. PUSATERI,JR.

United States Patent 3,518,615 ELECTRICAL CONNECTOR ASSEMBLY Harry P. Sparkes, Pacific Palisades, and Douglas F. Bowman and Anthony J. Pusateri, Jr., Canoga Park, Calif., assignors to Lockheed Aircraft Corporation, Burbank,

Calif.

Filed Apr. 17, 1967, ser. No. 631,475 Int. cl. Hon 13/58, 2.3/52

U.S. Cl. 339-94 6 Claims ABSTRACT OF THE DISCLOSURE A rugged electrical connector assembly having mating terminal sub-assemblies, wherein grouped conductor leads, in each sub-assembly, are physically isolated from each other according to their electrical phase relationship. As the terminal sub-assemblies are mated, the engagement of mounting plates disposed upon each sub-assembly act to remove moisture from the surface of the plates, thus creating a high resistance break in any possible electrical arcing path. Terminal heads on leads disposed within the housings are embraced by a segmented sleeve and arranged to resist mechanical failure due to vibration.

BACKGROUND OF THE INVENTION Field of the invention This invention relates generally to electrical connectors and more particularly to a connector having a high resistance to vibration, shock forces and ambient moisture.

The particular connector illustrated and described elow has been designed specifically to meet the rigorous operating conditions encountered in ship-to-shore electrical connections, although the connector can be readily used in other environments such as aircraft and guided missiles in which it may be subjected to severe moisture, vibration, or shock forces.

Description of the prior art Heretofore, the electrical power requirements aboard ship, when docked, have been met by means of the combustion of diesel fuel and/or coal. While these methods are satisfactory in some aspects, they are not only costly but necessarily create large amounts of residual contaminants which are normally expelled into the atmosphere.

While electrical connectors linking the ship with shorebased electrical power supplies have been proposed in the past (e.g., standard plugs, banana pins, etc.), their utilization and adoption has been severely limited by moisture which collects around the plugs, causing serious arcing effects to be produced. In such an environment the salt water in the surrounding air also has a great tendency to corrode the leads or plugs and thereby produce a poor connection. In addition, when the electrical cables and their associated connectors are disposed along the dock, moving vehicles and dollies in the vicinity can easily run over them, conceivably destroying the plug `and causing a black-out of an entire ship and causing a serious fire and electrical hazard.

SUMMARY OF THE INVENTION.

The invention relates generally to an electrical connector assembly. While it has particular utility in aircraft and ship-to-shore connections, and is explained hereinafter in the latter context, it also has direct application in many other areas. One of the important features of the connector requires that the mating parts of the connector create a wiping action as they are mutually engaged. Moisture is thereby removed and the connector is sealed Patented June 30, 1970 ICC to prevent further moisture from those areas adjacent the connector leads, thus reducing the possibility of electrical arcing. The connector leads are disposed according to phase and are so isolated in groups which are protected and sealed from one another by the mating portions of the assembly housings. The housings and their associated mounting plates are designed to withstand large surface forces as well as cable tension forces. Such potential forces are relieved by means of an angular buss arrangement which acts to reduce the amount of bending required to secure the cable to the housing.

It is, therefore, a primary object of this invention to provide a rugged electrical connector assembly, the mating parts of which, upon mutual engagement, act to remove 4moisture from areas surrounding the contact points.

Another object of this invention is to provide an electrical connector assembly suitable for ship-to-shore connections and which resists salt water corrosion of its contact points.

Another object is to provide an electrical connector of durable construction having buss means in stressrelieving relationship with its associated electrical cable.

Other objects and features of the invention will be apparent to those skilled in the art to which this invention pertains, upon reference to the following specification and accompanying drawings in which:

FIG. l is an external view of the connector assembly in its electrically connected position;

FIG. 2 is an enlarged sectional view of the connector assembly of FIG. 1 illustrating the assembly in the electrically connected position;

FIG. 3 is a view taken along line 3-3 of FIG. 2 showing the terminal assembly coniiguration of the present invention and partially cut away to illustrate the mounting plate attachment means;

FIG. 4 is a view taken along line 4 4 of FIG. 2 showing the receptacle terminal assembly configuration; and

FIG. 5 is another embodiment of the receptacle terminal assembly of FIG. 2, in partial section to illustrate a modified perpendicular attachment means of the outlet cable to the buss.

DESCRIPTION OF THE EMBODIMENTS Referring to FIG. 1 there is shown one embodiment of this invention generally comprising a connector assembly, as indicated by the arrow 10. The connector assembly 10 comprises a first terminal assembly 12 connected to a cable 15 and is formed as a receptacle unit and typically supported upon a bulkhead 13, together with a second terminal assembly 14, connected to a cable 16. The bulkhead 13 is, sometimes, in actuality a part of or attached to the hull of a ship, for example. The receptacle unit is usually covered when not in use, such as by a spring lock trap door or other conventional cover means.

A handle 17 is secured to or formed as a partof the terminal assembly 14 to provide a convenient handling means and to facilitate the connection and disconnection of the terminal assemblies without the necessity of gripping the cable 16. Opposite the connecting end of the terminal assembly 14 and attached to the handle 17 is a cable securing means 18 which acts to grip the cable 16 so that tension forces applied along the cable 16 are absorbed by the securing means 18 and are not transmitted to the wiring attachments within the assembly 14. The cable securing means 18 may, if desired, be formed as a part of the assembly 14 and is illustrated as a split collar 19.

Collar flange couplings 20 and 21, disposed at opposite ends of the split collar 19, have a series of apertures 22 defined therethrough such that when the collar 19 is about the cable 16, the apertures 22 are in register. The inner diameter of the collar 19 is smaller than the cable diameter which it surrounds to permit a clamping force to be applied to the cable 16. Fasteners 23 are disposed within registered apertures 22 and tightened an amount sufficient to cause the collar 19 to grip the cable 16 and act to relieve stress and tension forces transmitted thereby.

Referring to FIGS. 2-4, the terminal assemblies are configured for, and shown in, interlocking engagement. Each assembly 12 and 14 has a plurality of terminals 25 and 26, respectively, which, when in electrical communication, connect an electrical wiring network such as would be contained aboard a ship to a power supply means (not shown). The terminals 25 and 26 are shown disposed in three adjacent groups `with each group isolated from every other group by means to be described later. The purpose of this segregation is to permit each group to conduct one phase of a three-phase alternating current system without the danger of arcing between phase groups. Within each group there is little or no arcing, since the potential on each terminal is the same. Any moisture trapped within the assemblies 12 and 14 when the connection is made is isolated within the individual group. Thus, since each terminal within any one phase group is at a potential equal to every other suchy terminal, the voltage output would not be disturbed even if arcing within that group should occur. A standard potting material (not shown) could be used, if desired, to ll the interior of the assemblies 12 and give added rigidity thereto and also aid in the prevention of arcing between terminals.

The terminal assemblies 12 and 14 are surrounded by protective casings 24 and 27, respectively, which are made of a high resistance substance, such as rubber, that acts to shroud the entire internal mechanism of the assembly. The protective casing 27 has a neck portion 29 positioned adjacent the cable securing means 18 and adapted for receiving the cable 16. The neck 29 is in substantial register with the split collar 19 and is configured to retain the cable 16 while restricting the amount of ilexure thereof.

Opposite the neck portion 29 there is located at the mating end 31 of the terminal assembly 14 a shoulder region 32 circumferentially disposed about the periphery of the casing 27. The shoulder 32 is adapted so as to receive a terminal assembly mounting plate 33 which may be secured to the casing 27 by conventional means such as fasteners 34.

The terminal assembly mounting plate 33 has stepped inner and outer surfaces 35 and 36, respectively, and a plurality of apertures 38 therethrough which are suitable for receiving and containing commercially available terminals 25. Each group of apertures 38 is surrounded by a raised portion of the stepped surface 35 and a recessed portion of the stepped surface 36 and as a result is isolated from other groups and from the outer periphery of the casing 27. Consequently, as best shown in FIG. 3, any moisture which might collect around the outer mating portions of the assembly is effectively prevented from reaching the terminals 25.

The terminals 25, which are disposed within the apertures 38, have a threaded shank portion 39 which includes a cavity 40 into which a conventional seal 41 is inserted. Adjacent the shank 39 is a head portion 42 which has a diameter sufciently large to rest against a shoulder 43 within the aperture 38 when the terminal 25 is inserted therein. Opposite the shank 39 of the terminal 25 is a knob-shaped portion (not shown). The entire terminal lead 25 is usually fabricated from one piece of material such as hexagonal stock and is screwed into the mounting plate 33.

A buss 44, secured to the end of the cable 1-6 and in stress relieved relationship therewith, has a plurality of holes 45 disposed therein which mate with the apertures 38 of the plate 33. Each phase, of course, has its own buss and is sometimes keyed to a particular group of leads such as by means of a variation in the aperture pattern. The buss 44 is connected to the plate 33 by means of the terminals 25, which are screwed into the buss itself, while seal 41 acts to prevent the terminal 25 from becoming dislodged by bearing against the outer wall of the hole 45.

A split sleeve 46 is positioned within the aperture 38 and is of suflicient length to touch the shoulder 43 while terminating at its other end near the surface 36, so as to facilitate ease of connection between mating assemblies 12 and14.

The sleeve 46 surrounds the knob portion of the terminal 26 and is itself biased into tangential relationship with the terminal 25 by means of one or more garter springs 47.

The sleeve 46, terminals 25, and springs 47 are captured. Within the aperture 38 by means of covers 4S which is itself attached to the terminal assembly mounting plate 33 by conventional fastener means such` as screws 49. The covers 48 are preferably manufactured from a high resistance material such as plastic and have a series of apertures 50 located therein which are in register with apertures 38 when the cover 48 is mounted on the plate 33. The apertures 50 are of suflicient diameter to permit the knob portion of the terminals 25 to be inserted therein 'but are not large enough to permit the larger diameter sleeve 46 to pass therethrough.

Grooves 51 disposed on surface 36 each have a Seal 52 positioned therein thus insuring a iluid tight engagement between the mating assemblies 12 and 14. A raised portion of the stepped surface 35 also surrounds each buss in the interior of the assembly 27, thereby preventing internal arcing from occurring therein.

The receptacle terminal assembly 12, as best illustrated in FIGS. 2 and 4', has a surrounding protective casing 24, similar to casing 27, which terminates in a mating section 53 adjacent the assembly 14. The mating section 53 has a connecting ilange 54 disposed in circumferential relationship about the casing 24 and permits the receptacle terminal assembly 12 to be secured to utilization means such as the hull of a ship 13 as by threaded fasteners 55 or the like.

The mating section 53 has a flared flange 57 extending outward so as to guide the assembly 14 into engagement with the receptacle assembly 12. A shoulder 56, suitable forreceiving and retaining a mounting plate 58, is disposed within and adjacent the mating section 53. It is adapted to permit the securing to it of the plate 58 by conventional means, such as by fasteners 59. The mounting plate 58 has inner and outer stepped surfaces 60- and 61, respectively. The stepped surface 61 is configured so as to engage and mate with the surface 36 of the plate 33 at which time it is secured by any conventional fastener means. The mounting plate 58 has a plurality of apertures 63 Iwhich are in register with the apertures 38 when the assemblies 12 and 14 are connected.

A plurality of terminals 26 are screwed into the mounting plate 58 through apertures 63 and subsequently into a. buss 62. The buss 62 is connected to, and in electrical communication with, output cable 64. It is to be noted that the terminals 26 may be of varying lengths to create a selective switching arrangement and in order to provide sequential connection and disconnection as the terminal assemblies 12 and 14 are moved between their connected and disconnected positions. Since both mounting plates are provided with a stepped surface they can be reciprocally moved relative to one another until such stepped surfaces engage or until the terminal sleeves 46 engage the terminals 26.

As the mating terminal assemblies 12 and 14 are moved from a disengaged to an engaged position, the raised portions of the stepped surface 61 are placed in engaging relationship Within the groove 51 in the terminal assembly mounting plate 33 and bear against a seal 52 disposed therein. As the raised portion and the seal move into engagement a wiping action occurs, occasioned by the interference of the seal 52 and projecting ridges of the plate 58, whereby moisture which has collected around the cover 48 is removed from around its periphery; thus a high resistance path is created between each group of terminals, thereby restricting arcing, if any, to the terminals of each phase group,

It is to be specifically noted that the description contained herein has been limited to only one of the three phases involved since the other phases are identical in structure and function but the assembly would have equal application to a single phase system.

Referring to FIG. 5, a modified embodiment of the receptacle terminal assembly 12 is illustrated wherein the output cables 64 are connected to and disposed at an angle substantially normal to a buss 66.

The buss 66 at the end opposite the plate 58 has a yoke 68 which is adapted for receiving and retaining the cable 64. The insulation of cable 64 is removed adjacent the yoke 68 so that it is in electrical communication with the buss 66. The outer surface of the yoke 68 is threaded at its open end 70 so as to permit a nut 72 to be threadedly engaged thereon, A suitable retainer 74 is positioned intermediate the cable 64 and nut 72 and is of a length such that the nut 72, as it is tightened, causes the retainer 74 to be forcibly moved into biasing relationship with the cable 64.

It is to be understood that the invention herein shown and described is illustrative only and changes may be made in the shape, size and arrangement of parts without departing from the spirit of the invention as described or from the scope of the attached claims.

Having thus described our invention, what We claim and desire to secure by Letters Patent is:

1. An electrical connector comprising:

a first terminal assembly having a first mounting plate attached thereto, said first mounting plate having a stepped outer surface;

a second terminal assembly having a second mounting plate attached thereto, said second mounting plate having a stepped outer surface which is adapted for mutual engagement with said first mounting plate;

a plurality of terminals disposed within each of said Ifirst and second mounting plates, said terminals being arranged in groups and wherein each of said groups is sealed from each of the others by the mating portions of said stepped outer surface when said terminal assemblies are connected; and

a stepped inner surface on said mounting plate of said first terminal assembly disposed so as to segregate said terminals into groups.

2. An electrical connector as defined in claim 1 and including a dielectric cover plate mounted in a receiving aperture in said lirst mounting plate of said first terminal assembly, said dielectric cover plate having a plurality of apertures therein which are in register with corresponding ones of said terminals of said first terminal assembly, for retaining said terminals in said first mounting plate.

3. An electrical connector as defined in claim 1 including a buss connected to said mounting plate of said second terminal assembly, said buss having a threaded yoke disposed at its end opposite said mounting plate which is disposed in cable relieved relationship;

retainer means located within said yoke; and

fastener means threadedly secured to said threaded portion of said yoke; whereby as said fastener means is threadedly tightened on said yoke it forces said retainer means into biasing engagement with said cable thereby preventing its movement.

4. An electrical connector as defined in calim 1 including:

a stepped inner surface on said mounting plate on said second terminal assembly disposed so as to segregate said terminals into groups.

5. An electrical connector as defined in claim 4 and including means defining recesses on said stepped outer surface of said first plate so as to surround each terminal group mounted thereon;

sealing means disposed within said recesses; and

means upon said stepped outer surface of said second mounting plate defining raised portions so as to surround each of said terminal groups mounted thereon; whereby as said terminal assemblies are mated, each of said terminal groups is environmentally sealed from each of the other terminal groups and from external environment.

6. An electrical connector comprising:

first and second terminal assemblies having first and second mounting plates respectfully secured thereto, said mounting plates having stepped inner and outer surfaces, said outer surfaces being of complementary shape;

a plurality of terminals secured to each of said mounting plates, said terminals being disposed in groups and segregated by the stepped portions of said inner and outer surfaces and adapted to be placed in electrical communication with complementary groups in the other assembly when said assemblies are eneased;

a buss attached to said inner surface of said first mounting plate, said buss being in electrical communication with said terminals secured to said first mounting plate and being dismissed in stress relieved relationship with a cable electrically connected to a source of electrical power;

cable gripping means attached to said first terminal assembly and disposed intermediate said buss and said source of electrical power so as to facilitate stress relief of said cable; and

sealing means attached to said outer surface of said first terminal assembly and disposed about each of said groups of said terminals; whereby as said terminal assemblies are engaged a sealing is effected around each of said groups of said terminals thereby eliminating the possibility of a moisture path between groups.

References Cited UNITED STATES PATENTS 482,306 9/1892 Hall 339-49 X 2,421,155 5/ 1947 Miller et al. 339- 49 X 2,771,501 11/1956 Despard 339-103 X 3,064,226 11/1962 Cole 339-93 X 3,086,188 4/1963 Ross 339-49 3,307,138 2/1967 Swartz 339-94 X 2,291,793 8/ 1942 Chandler 339-60 2,411,861 12/1946 Antony et al. 339-111 2,858,518 10/1958 Chrystie et al. 339-111 X 3,124,405 3/ 1964 Massa 339-60 FOREIGN PATENTS 1,382,041 11/ 1964 France.

482,072 3/ 1938 Great Britain.

OTHER REFERENCES Electrical Mfg., July 1956, page 201, advertisement by The Pyle-National Co.

RICHARD E. MOORE, Primary Examiner U.S. C1. X.R. 339-103, 176 

